Manufacturing Engineer - Lost Foam
About The Position
The Manufacturing Engineer - Lost Foam will provide hands-on engineering support and technical ownership for a defined family of castings in Mercury Marine’s aluminum lost foam foundry at Plant 17. The role works across the value stream, from foam pattern production through finished cast parts, applying engineering fundamentals to improve safe, stable production and meet customer expectations. The engineer partners with operators and teams in foam molding, tooling, quality, maintenance, controls, machining, finishing, and other functions to resolve production challenges and improve processes. The position supports daily foundry production, analyzes operating data and process parameters, troubleshoots casting defects and variation, and leads or contributes to improvement initiatives. It also supports new casting program launches, drawing and specification review, and PPAP documentation, validation, and capability studies. The role is onsite in a foundry environment in Fond du Lac, Wisconsin, and does not require travel. It has no direct reports. The position is not eligible for visa sponsorship or relocation assistance. The hiring range is $62,800–$90,500 annually, with eligibility for an annual discretionary bonus.
Requirements
- Bachelor’s degree in Manufacturing, Mechanical, Industrial, or Metallurgical Engineering, or equivalent.
- Up to five years of manufacturing, engineering, foundry, or related experience.
- Demonstrated communication and interpersonal skills, with the ability to work effectively with cross-functional teams.
- Proficiency with Microsoft 365, including Excel, Teams, SharePoint, and Planner.
Nice To Haves
- Coursework related to metal casting, lost foam, sand molding, foundry processes, or manufacturing engineering.
- Experience with PLCs, industrial controls, Allen-Bradley systems, ABB robotics, Ignition, SQL, Power BI, process traceability, shop-floor dashboards, data collection systems, or advanced inspection technologies.
- Experience with 3D CAD software and the ability to review part, pattern, tooling, and manufacturing designs.
- Familiarity with Lean Manufacturing, Six Sigma, statistical process control, or structured problem-solving methods.
- Strong analytical and problem-solving skills, including using data and sound engineering judgment to make decisions.
- Ability to deliver results independently and as part of a cross-functional team.
- Demonstrated project management skills and ability to manage multiple priorities.
- Team-oriented mindset, ability to learn quickly, and ability to thrive in a foundry environment.
- Ability to work in a fast-paced, constantly evolving manufacturing environment with limited oversight.
- Willingness to evaluate and implement new processes, systems, and technologies.
Responsibilities
- Provide hands-on engineering support and subject matter expertise for a defined family of lost foam castings across the manufacturing process.
- Monitor, collect, and analyze operating data to understand the effects of process parameters and identify improvement opportunities.
- Provide day-to-day production support by troubleshooting casting defects, process variation, and upstream or downstream conditions.
- Lead and support continuous improvement focused on defect reduction, process stability, productivity, cost reduction, ergonomics, and safety.
- Evaluate how operations throughout the lost foam value stream affect final part quality, including foam molding, cluster preparation, coating, sand, compaction, pouring, extraction, finishing, machining, leak testing, and painting.
- Collaborate with operations, quality, maintenance, controls engineering, tooling, and project management teams to implement process improvements.
- Support new casting program launches with DFM input and participation in tooling, simulation, process development, validation, and part review activities.
- Read and interpret casting and machining drawings, tolerances, specifications, CMM reports, inspection results, and other technical requirements.
- Contribute to PPAP activities, including process documentation, validation, capability studies, and customer requirements.
Benefits
- Annual discretionary bonus eligibility.
- Medical insurance.
- Dental insurance.
- Vision insurance.
- Paid vacation.
- 401(k) with up to 4% company match.
- Health Savings Account with company contribution.
- Well-being program.
- Product purchase discounts.
- Growth opportunities within and across Brunswick brands.
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What This Job Offers
Job Type
Full-time
Career Level
Entry Level
